Why vibration probes are installed in X-Y manner?

Use orbit, timebase, and shaft centerline plots to display shaft motion. The most common use for the orbit, timebase, and shaft centerline plots is to monitor turbomachinery with fluid film bearings. Some turbomachinery mechanical faults have characteristic plot shapes. You can compare the acquired plots with any known characteristics to detect faults and diagnose machine problems.

You mount two proximity probes orthogonally on a fluid film bearing to acquire the signals for the orbit, timebase, and shaft centerline plots. An orbit plot shows the dynamic motion of the center of a rotating shaft with signals from two proximity probes. A timebase plot displays dynamic vibration amplitude information with the same proximity probe signals as the orbit plot. The timebase plot displays the signals as a function of time in one or more revolutions with two separate plots. A shaft centerline plot displays the shaft center DC position changes within a bearing clearance range. An orbit plot represents the shaft center AC dynamic motion. Use a shaft centerline plot with an orbit plot to track both aspects of shaft motion.

The following illustration shows how you might configure a system to display an orbit plot and a shaft centerline plot.

 

In the previous illustration, two orthogonally-mounted proximity probes measure the shaft motion. The outer circle depicts the bearing clearance. As the shaft speeds up in the counterclockwise (CCW) rotation direction, the shaft center moves from the bottom of the bearing clearance to the normal operational center, as the Shaft Centerline shows. As the shaft continues in normal operation, the shaft center moves around the normal operating center, as the Shaft Orbit shows.

Orbit Plot

An orbit plot generates a two-dimensional image of the shaft center motion. Use the OA Orbit Plot VI to display both filtered and unfiltered orbit plots. An unfiltered orbit plot displays the shaft motion based on even-angle signal data. The unfiltered plot shows the direct motion of the shaft center and displays all orders. A filtered orbit plot displays the shaft motion based on vector signal data. The filtered plot shows the synchronous motion of a particular order.

The following illustration shows a filtered orbit plot and the typical setup for monitoring a rotating shaft with an orbit plot.

The X and Y proximity probes, which are two probes of the same type mounted 90 degrees apart, monitor the shaft. If you do not use two orthogonally-mounted probes, the orbit plot might appear skewed.

Probe Angle Correction

In many cases, you cannot mount probes easily in the desired 90 degrees out of phase horizontal and vertical orientation. Probes often have a 45-degree deviation instead. The following illustration shows the common mounting positions for X and Y probes.

 

An orbit plot assumes that the signals are from probes in true horizontal and vertical positions. To display data with respect to a true vertical and horizontal coordinate system, you must rotate the data by the probe angular offset from the desired coordinates. The following illustration shows the effect of compensating for a 45-degree mounting position.

 

You can use the OAT Orbit Plot VI to rotate an orbit plot to the true horizontal and vertical probe orientations.

Timebase Plot

A timebase plot displays the vibration amplitude of one or more revolutions of a shaft as a function of time. Whereas an orbit plot shows the whole picture of the rotating shaft, a timebase plot enables you to get a clearer picture of what an individual transducer acquires in terms of vibration amplitude. The timebase plot follows the same convention as the orbit plot. The following front panel shows a typical unfiltered timebase plot for the x-axis and y-axis.

In the previous plot, each dot represents the trigger pulse position.

Use the OA Timebase Plot VI to display both unfiltered and filtered timebase plots. An unfiltered timebase plot displays the shaft vibration with an even-angle signal. A filtered timebase plot displays the shaft vibration with a vector signal. The filtered timebase plot shows only the synchronous motion of a certain order.

Shaft Centerline Plot

Use a shaft centerline plot to display changes in radial rotor position with respect to a stationary bearing over a range of time or speed. The DC gap voltage from two orthogonally-mounted proximity probes determines the averaged position change. The following illustration shows a typical shaft centerline plot of a machine startup.

The numeric values on the above plot correspond to the rotational speed.

Displaying a Shaft Centerline Plot

You can use the OAT DC Gap Estimator VI to compute the DC gap values from the X and Y proximity probes. You then can use the OAT Shaft Centerline Plot VI to display the shaft centerline plot with DC gaps.

The shaft centerline plot follows the same true vertical and true horizontal convention as the orbit plot. You can use the OAT Shaft Centerline Plot VI to rotate the plot to true vertical and true horizontal positions.

When displaying a shaft centerline plot, you must specify the bearing clearance and shaft centerline starting point reference. Three types of starting point references are as follows:

• Bottom—Use the bottom starting point reference for a horizontal machine train.
• Center—Use the center starting point reference for a vertical machine train.
• Top—Use the top starting point reference for overhung rotors, such as fans and compressors.

The following illustration shows three shaft centerline plots with different start point references.

You can see that the starting point reference you choose affects the boundary position of the bearing clearance in a shaft centerline plot.

Vibration measurement fundamentals

1. The following comments apply to a the application of machinery protection and asset management systems for rotating machinery with hydrodynamic or fluid film bearings. The extent to which various parameters are recommended to be measured (and monitored) is directly proportional to how critical the machinery asset is to the continued, uninterrupted operation of the plant or process.  For example, some machines such as turbine generators, compressors, and larger mechanical drive steam turbines, are found in the critical paths of many plant processes. Other types such as small motors, pumps and fans are non-critical or semi-critical machines. Therefore, the  recommendations for monitoring compressors will generally be more rigorous and extensive than those for fans. Machine measurements must be correlated with process variable measurements in order to obtain a complete understanding of machinery behavior as well as providing adequate machinery protection.

2. The bearing type plays an important role in determining what the appropriate transducer suite should be.  For example, semi-critical or non-critical machinery with rolling element bearings are usually adequately monitored via a single seismic transducer mounted radially at each bearing.  Rolling element bearings have little or no damping which usually results in good transmissibility of the rotor’s vibration to the casing and due to the mechanical nature of the bearing itself, when it fails inevitably the vibration amplitude will increase.  However, this is not the case for turbomachinery with hydrodynamic (fluid film) bearings.  In order to properly monitor critical turbomachinery operating in hydrodynamic or fluid film bearings the shaft relative measurement utilizingproximity (displacement) probes must be a part of a properly engineered offering.   XY (orthogonal; i.e. at 90°) proximity probes at each radial bearing are mandatory.  There are no exceptions to this rule.   From an engineering principle / best practices perspective it would not be acceptable to only use one proximity probe as opposed to installing two proximity probes, orthogonally mounted (90° apart).  If only one probe is installed, dyanmic motion (vibration) will only be seen in the same plane as the longitudinal axis of the installed probe; i.e. in line with the transducer.   

3. Reminding ourselves of the 1^st Law of Machinery Diagnostics which states that Displacement = Force / Stiffness we recognize:

i. If the force (a vector quantity) changes, the displacement (also a vector quantity) will change

ii. Likewise if the force remains constant, but the stiffness (also a vector quantity) changes, the displacement will change

4. Let’s focus on the second item for just a moment.  In the presence of a constant force due to unbalance[1] and an asymmetrical support stiffness[2] which exists with most turbomachinery, we realize that the resulting vibration displacement will vary as the constant unbalance force rotates and encounters a continually varying, asymmetric support stiffness.  If we were to plot this motion, we would generate an elliptical shape; i.e. the shaft relative orbit, which would accurately depict the motion of the centerline of the shaft in the radial or xy plane.  Maximum vibration will occur along the major axis of the ellipse (plane of lowest support stiffness) while along the minor axis of the ellipse, the vibration response will be at its minimum because the support stiffness is maximum.  More than likely, the major axis of the ellipse (plane of maximum shaft vibration) will not be aligned with either the x or y proximity probe.  Consequently by itself, as a single plane measurement, neither probe will see the maximum vibration.  However, it can be observed by noting the vibration amplitude along the major axis of the ellipse or by calculating S_max.  However, in order to either generate the shaft relative orbit or calculate S_max,  xy transducers must be installed at 90°.  These measurements cannot be made with a single plane measurement.  The worst case scenario occurs when the major axis of the ellipse (plane of maximum vibration) is rotated 45° with respect to the angular location of the proximity probe.  For this case, the proximity probe will only see 71% of the maximum vibration because the plane of maximum vibration is rotated 45° from the axis of the transducer.

5. The following vibration signal characteristics are critical when evaluating the health of  turbomachinery operating in hydrodynamic bearings:

· overall vibration amplitude

· vibration frequency

· filtered vibration amplitude; i.e. 1X, 2X, nX  (requires once per turn phase trigger probe as a phase reference)

· determining actual maximum vibration amplitude (requires xy proximity probes)

· shape or form of the vibration, i.e. orbit  (requires xy proximity probes)

· vibration precession; vibration either in the direction of or opposite of the direction of rotation  (requires xy proximity probes)

· rotor operating deflection and  / or mode shape  (requires xy proximity probes)

· shaft average centerline radial position (requires xy proximity probes)

· identification and evaluation of support stiffness asymmetry  (requires xy proximity probes)

· full spectrum  (requires xy proximity probes)

· S_max vibration amplitude  (requires xy proximity probes)

6. It should be noted that the selection of any transducer / monitoring / protection / information system often involves compromises.  There is a point that must be made at this time.  There are no absolutes and there is no one machinery protection or management system that is adequate or capable of detecting any and all machinery malfunctions or potential failures.  The recommendations offered here apply universally to the most common design configurations and process applications, but as with any general set of rules, there will be exceptions.  There always is and always will be a trade-off between the complexity of the transducer suite / monitoring and / or information systems and the economic justification for enhanced performance of the protection / information system.  The technical priorities are weighed against the economic considerations and a decision is made.  

7. In general, it is important to recognize that in order to determine the optimum protection system for any turbomachinery train, each piece of machinery must be evaluated individually. Often adequate data is not available for a detailed analysis of a particular machine's expected behavior under normal and malfunction conditions. It then becomes necessary to use sound engineering principles in order to “install what is right” as opposed to “install what is easy”.

8. End users should fully understand the value of the information that the transducer suite / vibration monitoring system is providing to them and how to turn this information into productive tasks and actions.  At times, end users are  not aware of the total information that is available from a properly engineered, installed, and commissioned transducer suite / machinery protection system.  Having the correct information at the right time is mandatory in order to properly manage units in order to achieve the desired unit availability goals, mitigate risk, and better plan for upcoming outages.

9. A good tool to use to evaluate where you are is a “risk assessment”. It starts with a careful evaluation of all relevant data to determine current status, where the end user wants (or needs) to go, and what needs to be done so that the end user can achieve the established goal(s). One deliverable from the risk assessment is a prioritized action plan. This action plan should communicate whether the current transducer suite / machinery protection system(s) is adequate. 

At a minimum, the risk assessment should include:

•          A review of current business objectives and contractual obligations.

•          Quantify past and present unit performance, maintenance history, and unit availability.

•          Review and quantify previous operational, maintenance and machinery failures and their impact on unit availability.

•          Review existing data relative to any previous failures, maintenance history and unit availability.

•          Evaluate current system status and capabilities.

•          Quantify expected return on investment of expected changes or improvements.

_________________________________________________________________________________

[1] A fixed mass at a fixed radius rotating at operating speed generating a constant, uniform force in all directions

[2]Nnon-uniform support stiffness; i.e. different vertical support stiffness vs. horizontal stiffness.

Power and Control Cables

POWER / CONTROL CABLES

Voltage Grade	-	Upto 1100 V
Cores	-	Single / Multicore
Conductor	-	Electrolytic grade copper Bare / Tinned, Solid / Stranded / Flexible conductors.
Range	-	Single Core 1.5 to 400 Sq.mm, Multi Core upto 50 Sq.mm, 1.5 Sq.mm & 2.5 Sq.mm. upto 61 Cores.
Primary Insulation	-	General Purpose PVC / Hear Resistant PVC / LDPE / XLPE / LSF /PTFE / Fibre Glass.
Inner Sheathing	-	PVC / HRPVC / FR PVC / FRLS PVC / ZHFR / LSF / Fibre Glass
Armouring	-	GI Round Wire / Flat strip.
Outer Sheathing	-	General purpose PVC / HRPVC / FRLS PVC / ZHFR
Standards	-	IS - 694, IS – 1554 (Part-I), IS-7098 (Part-I) & IEC 60502-1, IEC-60332.

CORE Identification

Cores shall be identified by different colours of PVC insulation. Following colour scheme shall be adopted -
1 Core	-	Any Single colour.
2 Cores	-	Red and Black.
3 Cores	-	Red, Yellow & Blue.
4 Cores	-	Red, Yellow, Blue & Black.
5 Cores	-	Red, Yellow, Blue, Black & Grey.
6 Cores and above	-	Two adjacent cores (counting and direction core) in each layer, Blue And Yellow, remaining cores Grey.
In addition to these, combinations from the following colours can also be offered - Red, Black, Blue, Green, Grey, Orange, Violet, White, Yellow. Alternately, any single colour insulation on all cores with number printing can also be provided.

Designation Code

Y	--	PVC insulation
W	--	Steel round wire armour
F	--	Steel strip armour
WW	--	Steel double round wire armour
FF	--	Steel strip double armour
Y	--	PVC outer sheath
A	--	Aluminium conductor

No Abbreviations used when the conductor material is Copper.

Thermocouple Cables

THERMOCOUPLE EXTENSION / COMPENSATING LEADS CABLES

Voltage Grade	-	Upto 1100 V
Cable Code	-	KX, KX(A), TX, JX, EX, SX /RX, BX, NX, UX, WX
Construction	-	Single or Multiple Pairs
Range	-	16 AWG / 18 AWG / 20 AWG / 20 AWG upto 20 Pair
Primary Insulation	-	General purpose PVC / HEAT RESISTANT PVC / LDPE / XLPE / PTFE / Fibre Glass / XLPE
Screening	-	Individual and / or overall with Aluminium Mylar / Copper Tape or with Tinned, Bare, Nickel Copper / Stainless Steel
Inner Sheath	-	PVC/ HRPVC / FR PVC / FRLS PVC / ZHFR / LSF / PTFE / Fibre Glass / ZHFR.
Armouring	-	GL round Wire / Flat strip
Outer sheath	-	PVC / HRPVC / FR PVC / FRLS PVC / ZHFR / LSF / PTFE / Fibre Glass / ZFHR.
Standards	-	ANSI:MC-96.1, IS-8784, DIN, BS, IEC 584-3 AND IEC-60332
Rip cord	-	For easy removal of sheath.

Instrumentation Cables

Instrumentation Screened Cables & Thermocouple Compensating Cable Sl No. 1 Pair X 1.5mm2 Signal Cable 2 Pair X 1.5mm2 Multicore Signal Cable 12 Pair X 0.5mm2Multicore Signal Cable 1 Pair X 1.5mm2 T/C Extn. Cable/ Comp. Cable 6 Pair X 0.5mm2 T/C Extn. Cable/ Comp. Cable 12 Pair X 0.5mm2 T/C Extn. Cable/ Comp. Cable 1 Triad X 1.5mm2 RTD Signal Cable 6 Triad X 0.5mm2 RTD Signal Cable 3 Core X 1.5mm2 Power Cable (Armoured & Screened) (Armoured & Screened) (Armoured & Screened) (Armoured & Screened) (Armoured & Screened) (Armoured & Screened) (Armoured & Screened) (Armoured & Screened) (Unscreened Armoured ) 1. General Application Std. BS5308(Part-2) IS-8130 / 84 Yes Yes Yes Yes and Yes and Yes and IS-8130/84 IS-8130/84 IS-8130/84 IS-5831 / 84 ANSI-MC 96.1 ANSI-MC 96.1 ANSI-MC 96.1 IS-3975 / 88 2. Voltage Grade (RMS) Volts 660 / 1100 V 660 / 1100 V 660 / 1100 V 660 V 660 V 660 V 660 / 1100V 660 / 1100V 1100 V 3. Operating Temp. in Deg. C 90 90 90 90 90 90 90 90 90 Numbers of Cores/Pairs / Triad 1 Pair 2 Pair 12 Pair 1 Pair 6 Pair 12 Pair 1 - Triad 6 - Triad 3 core (A) CONDUCTOR Material & Standard Annealed Copper Annealed Copper Annealed Copper +VE Chromel/ Copper/ -VE Alumel/Cu-Ni Alloy +VE Chromel/ Copper/ -VE Alumel/Cu-Ni Alloy +VE Chromell/ Copper/ -VE Alumel/Cu-Ni Alloy Annealed Copper Annealed Copper Annealed Copper Conforming To IS - 8130/84 IS - 8130/84 IS - 8130/84 ANSI MC. 96.1/ IS : 8784-1987 ANSI MC. 96.1/ IS : 8784-1987 ANSI MC. 96.1/ IS : 8784-1987 IS - 8130/84 IS - 8130/84 IS - 8130/84 Grade Electrolytic Electrolytic Electrolytic KX / KX(A) KX / KX(A) KX / KX(A) Electrolytic Electrolytic Electrolytic No. of Strand/Dia of each Strand (mm) 48/0.2 OR 7/0.53 48/0.2 OR 7/0.53 16/0.2 OR 7/0.3 1/16 AWG 1/20 AWG 3x22 SWG 1/16 AWG 1/20 AWG 3x22 SWG 1/16 AWG 1/20 AWG 3x22 SWG 48/0.2 OR 7/0.53 16/0.2 OR 7/0.3 48/0.2 OR 7/0.53 Pair Identification (by Number markings on Cores at an interval of 250 mm or by number tape on each Core) Yes Yes Yes Yes Yes Yes Yes Yes Yes Form of Conductor Round Round Round Round Round Round Round Round Round Area of Cross Section (sq. mm) 1.5 1.5 0.5 1.5 0.8 OR 1.5 0.8 OR 1.5 1.5 0.5 1.5 Insulation Resitance at 20oC Meg. Ohms/Km (min.) 100 100 100 100 100 100 100 100 100 Inductance (Max) Millnry/Km 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 N.A. L/R Ratio (Max) Microhenry/Km 40 40 25 40 25 25 40 25 N.A. Communication Pair NO NO YES NO YES YES NO YES NO (B) INSULATION Insulation PVC Type-A or C 0.6mm nominal thickness to IS-5831/84 Yes Yes Yes Yes Yes Yes Yes Yes yes Colour Code BS:5308(Part-2) or ANSI or IS:8784 Yes Yes Yes Yes Yes Yes Yes Yes yes Tolerance on drum length (+/-5%) Yes Yes Yes Yes Yes Yes Yes Yes Yes Bending Radius 12 X 0.0 Yes Yes Yes Yes Yes Yes Yes Yes Yes (C) SCREENING / SHIELDING (individual + overall) for multi pair Material Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape Aluminium Backed Mylar Tape N.A. Percentage Coverage 100% 100% 100% 100% 100% 100% 100% 100% N.A. Overlap % 25% 25% 25% 25% 25% 25% 25% 25% N.A. Thickness (mm) min. 0.05 Yes Yes Yes Yes Yes Yes Yes Yes N.A. (D) INNER SHEATH Material PVC / HR PVC FRLS Yes Yes Yes Yes Yes Yes Yes Yes Yes Type & Standard to which IT conforms IS-5831/84, ASTM, IEEE Yes Yes Yes Yes Yes Yes Yes Yes Yes Extruded (Yes) Yes Yes Yes Yes Yes Yes Yes Yes Yes Thickness Min. (mm) 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 Colour BS: 5308(Part-2) Yes Yes Yes Yes Yes Yes Yes Yes Black Ripchord shall be provided Yes Yes Yes Yes Yes Yes Yes Yes Yes (E) ARMOURING Material &Type of Armour (Galvanised Steel Wire / Strip) Yes Yes Yes Yes Yes Yes Yes Yes Yes Standard to which it conforms IS-3975/88 Yes Yes Yes Yes Yes Yes Yes Yes Yes Size 0.9 mm 0.9 mm 4x0.8 mm 0.9 mm 4x0.8 mm 4x0.8 mm 0.9 mm 4x0.8 mm 1.4 mm Direction (Left Hand) Yes Yes Yes Yes Yes Yes Yes Yes Yes (F) OUTER SHEATH Material : PVC / HR PVC / FRLS Yes Yes Yes Yes Yes Yes Yes Yes Yes Type & Standard to which it conforms IS-5831/84, ASTM, IEEE Yes Yes Yes Yes Yes Yes Yes Yes Yes Thickness min/nominal (mm) 1.4 1.4 1.8 1.4 1.8 1.8 1.4 1.6 1.4 Colour Electrical chracteristics (Reqd. for intrinsic safety) L. Blue L. Blue L. Blue Brown Brown Brown L. Blue L. Blue Black (G) ELECTRICAL PARAMETER Conductor Resistance (DC) max. at 20 Deg. C Ohm/Km for each Core 12.2 12.2 36.6 Loop 0.4 / mtr 0.6 / mtr Loop 0.4 / mtr 0.6 / mtr Loop 0.4 / mtr 0.6 / mtr 12.2 36.6 12.2 Mutual Capacitance (Max) p F/Km Between Cores 250 250 75 250 75 75 250 75 N.A. Between Core to Screen 400 400 120 400 120 120 400 120 N.A. (H) CHARACTERISTICS OF FRLS SHEATH : (A) Oxygen Index : Minimum 29% at Room Temperature when tested as per ASTM-D-2863 (B) Temperature Index : Minimum 250 Deg. C at Oxygen Index when tested as per ASTM-D-2863 (C) Acid Gas Generation : Minimum 20% by weight when tested as per IEC-754 Part-1 (D) Smoke Density Rating : Minimum 60% when tested as per ASTM-D-2843 (E) Flammability Test As per IEC 332 Part 1 & 2 / 1979